Processing porous prototype models in CNC is a key link in product development, widely used in automotive parts, 電子エンクロージャー, および医療機器プロトタイピング. Mastering the skills to process porous prototype models in CNC can ensure the accuracy of hole positions, reduce material waste, and speed up the prototype verification cycle. This article will explain the whole process in detail and provide practical solutions to common problems.
1. Design and Programming: 精度の基礎を築きます
The first step to process porous prototype models in CNC is to complete scientific design and accurate programming—this directly affects the final hole position accuracy and machining efficiency.
Specific Operations
- Use professional CADソフトウェア (SolidWorksなど, Autocad) to design the 3D model of the porous prototype. During the design, pay special attention to the spacing between holes, hole depth, and the connection between holes and other structures to avoid design conflicts.
- Import the 3D model into CAMソフトウェア (Mastercamのように, UG). The software will automatically generate CNC code, which clearly defines important parameters such as drilling position (coordinates of each hole), drilling depth (例えば。, 5mm for through-holes, 3mm for blind holes), spindle speed (素材によって異なります), and machining sequence (usually from shallow to deep, from edge to center).
場合: When processing a porous aluminum alloy electronic enclosure prototype, engineers used SolidWorks to design 20 M3 threaded holes (hole depth 8mm, hole spacing 15mm). After importing into Mastercam, the CAM software generated code that set the machining sequence to start from the four corner holes and then process the middle holes, effectively avoiding material deformation caused by uneven stress.
2. Material and Tool Selection: Match Requirements for Efficiency
Choosing the right materials and tools is a prerequisite for smooth processing of porous prototype models in CNC. Improper selection will lead to problems such as tool breakage and unqualified hole quality.
マテリアル選択ガイド
| 材料タイプ | 利点 | Suitable Prototype Scenarios | 機械加工の難易度 |
| ABSプラスチック | Light weight, 低コスト, 機械加工しやすい | Low-load structural prototypes (例えば。, プラスチックエンクロージャー) | 低い |
| PCプラスチック | 耐衝撃性が高い, 耐熱性 | Prototypes for high-temperature environments (例えば。, automotive instrument panels) | 中くらい |
| アルミニウム合金 (6061) | 良い剛性, good thermal conductivity | High-precision structural prototypes (例えば。, 機械部品) | 低い |
| ステンレス鋼 (304) | 耐食性, 高強度 | Prototypes for harsh environments (例えば。, 医療機器) | 高い |
Tool Selection Tips
- For plastic materials (腹筋, PC), 選ぶ high-speed steel (HSS) ドリル with a diameter 0.1-0.2mm smaller than the designed hole diameter (to compensate for material expansion during machining).
- For metal materials (アルミニウム合金, ステンレス鋼), 使用 carbide drills—they have higher hardness and wear resistance. For stainless steel, it is recommended to choose drills with a special spiral angle (30°-40°) to improve chip removal efficiency.
3. Setup and Fixing: Ensure Stability to Reduce Errors
Unstable fixing of materials and incorrect tool installation will cause displacement during machining, resulting in deviations in hole positions. The following steps can ensure stable setup:
- 材料の修正: Place the material on the CNC workbench and use fixtures (such as vises, pressure plates) to fix it. For thin materials (thickness less than 3mm), add a backing plate under the material to prevent the drill from piercing the workbench. After fixing, check the material with a dial indicator—ensure the runout is within 0.02mm.
- Tool Installation: Install the selected drill on the CNC spindle. Use a tool setting gauge to calibrate the tool length (to ensure accurate drilling depth) and tool radius. After installation, run the spindle at low speed (500r/min) のために 10 seconds to check if the tool runs smoothly without eccentricity.
4. Process Monitoring and Adjustment: Real-Time Optimization for Quality
During the processing of porous prototype models in CNC, real-time monitoring and parameter adjustment can timely solve problems and avoid batch defects.
Key Monitoring Points and Adjustment Methods
- スピンドル速度: If the spindle speed is too high (例えば。, 8000r/min for aluminum alloy), the tool will wear quickly; if it is too low (例えば。, 2000r/min for aluminum alloy), the hole surface will be rough. The normal spindle speed range for aluminum alloy is 4000-6000r/min, and for stainless steel is 1500-3000r/min.
- フィードレート: For plastic materials, the feed rate can be set to 100-200mm/min; for metal materials, it is 50-150mm/min. If the feed rate is too fast, the drill may break; if it is too slow, the machining time will be prolonged.
- Chip Removal: 機械加工中, observe the chip shape. For metal materials, continuous chips indicate normal processing; if the chips are broken into small pieces, it may be that the feed rate is too fast, and the feed rate needs to be reduced by 20%-30%.
5. Quality Control and Post-Processing: Improve Prototype Performance
After processing, strict quality control and appropriate post-processing can make the porous prototype meet the design requirements.
Quality Control Items
- 目視検査: Check if there are burrs, ひび割れ, or incomplete drilling around the holes.
- 寸法検査: Use a caliper to measure the hole diameter (tolerance should be within ±0.05mm) and a coordinate measuring machine (CMM) to detect the hole position accuracy (error should be less than 0.03mm).
後処理ステップ
- deburring: Use a file or sandpaper (400#) to polish the burrs around the holes—this is especially important for threaded holes to avoid affecting the installation of screws.
- クリーニング: Use alcohol or acetone to clean the prototype surface to remove cutting fluid and chips.
- 表面処理: 金属プロトタイプ用, perform oxidation (アルミニウム合金) or passivation (ステンレス鋼) treatment to improve corrosion resistance.
Yigu Technology’s Perspective on Processing Porous Prototype Models in CNC
Yiguテクノロジーで, we think processing porous prototype models in CNC requires the combination of design precision and practical experience. Many clients have problems like hole position deviation due to ignoring material fixing or tool calibration. We suggest using our self-developed CNC machining simulation software to test the program before formal processing, which can reduce 30% of trial machining errors. その間, our customized carbide tools for porous machining can improve tool life by 40% and machining efficiency by 25%, helping clients shorten the prototype development cycle.
よくある質問
- Q: What should I do if the hole position is deviated when processing porous prototype models in CNC?
a: 初め, check if the material is fixed tightly—re-fix if it is loose. それから, use a tool setting gauge to re-calibrate the tool length and radius. If the deviation still exists, check the CAM code for errors in hole coordinates and modify it if necessary.
- Q: Can I use the same tool to process holes of different diameters in a porous prototype?
a: It is not recommended. Using a tool with a fixed diameter to process holes of different sizes will lead to unqualified hole diameters. You should prepare tools corresponding to each hole diameter to ensure the accuracy of each hole.
- Q: How to avoid tool breakage when processing deep holes (depth > 10mm) in porous prototypes?
a: Adopt the “segmented drilling” method—drill 3-5mm each time, then lift the tool to remove chips. At the same time, increase the flow of cutting fluid to cool the tool and improve chip removal efficiency. Choose a drill with a longer flute to facilitate chip discharge.
